Control modules for electronic systems and consoles formed thereby

ABSTRACT

A control console formed by a family of modular sub-sections, each including a box-like housing formed by four pieces, one of which is a flat sheet bendable into a channel to define the rear and the top and bottom walls, the second and third of which are identical end pieces to define the end walls, and the fourth of which is the front panel of the housing. All of these pieces are of the same width and may therefore be stocked in strip form, but the channel and panel pieces may be cut to different lengths, whereby housings formed by fastening the pieces together may differ in length but are otherwise of the same dimensions. When such modules of different length are arrayed in side-by-side relation, they present a continuous integrated appearance. A console skeleton is provided which is adapted to clamp together an array of modules, the clamp being releasable whereby individual modules may readily be removed and replaced.

ilnite taes atent 1191 Layton et a1 Oct. 2, 1973 N.Y.; Kenneth '1.Yocis, New Milford, Conn.

[73] Assignee: linterlab, 1nc., Danbury, Conn.

[22] Filed: Mar. 6, 1972 [21] Appl. No.:231,9410

52 us. ca. 317/11117, 317/101 CB, 312/108 51 111111.131. 11021) 11/04,1-105k 7/16 [58 Field 01 Search 317/101 CB, 117, 317/120, 99;,312/07,108, 198, 263; 338/197,

['56] References Cited 'UN1TED STATES PATENTS 12/1964 Davis 312/1076/1969 Anders. 312/198 X 8/1969 Meyer 312/120 Primary Examiner-Robert K.Schaefer Assistant Examiner-Gerald P. Tolin AttorneyMichael Ebert 1571ABSTRACT A control console formed by a family of modular subsections,each including a box-like housing formed by four pieces, one of which isa flat sheet bendable into a channel to define the rear and the top andbottom walls, the second and third of which are identical end pieces todefine the end walls, and the fourth of which is the front panel of thehousing. All of these pieces are of the same width and may therefore bestocked in strip form, but the channel and panel pieces may be cut todifferent lengths, whereby housings formed by fastening the piecestogether may differ in length but are otherwise of the same dimensions.When such modules of different length are arrayed in side-by-siderelation, they present a continuous integrated appearance. A consoleskeleton is provided which is adapted to clamp together an array ofmodules, the clamp being releasable whereby individual modules mayreadily be removed and replaced.

5 Claims, 7 Drawing Figures Patented Oct. 2,1973

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WWW! Z""HW"lmiliiliinn Patented Oct. 2, 1973 3 Sheets-Sheet Z CONTROLMODULES FOR ELECTRONIC SYSTEMS AND CONSOLES FORMED TI'IEREIIY BACKGROUNDOF THE INVENTION This invention relates generally to control panels andconsoles, and more particularly to a control console constituted by afamily of modular sub-sections.

In electronically-controlled industrial systems, the various controlknobs and dials, the push-button and toggle switches, and theindicators, are usually mounted on a common control panel or console.Similarly, in complex process control equipment, the usual practice isto group together on a single control panel, the various manuallyoperated control dials as well as meters, pilot lights and other controland indicator elements.

By placing all of the control and indicating elements in one convenientlocation, operation of the system is facilitated and its installationand maintenance are simplified. In terms of human engineering andindustrial design, centralization of all controls on a console controlpanel imparts a more pleasing appearance to the installation and makespossible more efficient supervision thereof.

When a company is engaged in manufacturing complex multi-stage processequipment in diversified forms intended for use at a single industriallocation, manufacturing procedures and routine maintenance can beimproved considerably by breaking down the central control panel into afamily of sub-sections of standardized design.

For example, let us assume that at a given plant, parts are to beprocessed at a series of work stations, each carrying out a distinctfunction. Associated with each station are switches, dials, meters, andother control and indicating elements appropriate to the stationsfunction.

Rather than merge all of the control and indicating elements related tothe several stations on a single control panel, the better practice isto provide a separate control sub-section or module for each station,the module containing all of the control elements related to itsassociated station, and to then assemble a family of such modules on acommon console.

With this modular approach, one can conveniently put together customprocessing systems using standard control modules. For example, at oneinstallation, the need may exist for cleaning, coating, heating andplating stations and control modules therefor, whereas in anotherinstallation, the need may be for cleaning,

' rinsing, and cooling stations. By using standard modules selected forthe particular system, one may assemble a system meeting specifiedrequirements. In a modular system of this type, control sub-sections ormodules may be readily replaced in their entirety to avoidtrouble-shooting control equipment failures at their point of use.

SUMMARY OF THE INVENTION The main obect of this invention is to providea module housing formed by four standardized pieces that may be stockedin flat form and readily converted into box-lilac enclosures when theneed arises.

More specifically, it is an object of this invention to provide ahousing for a module constituted by a flat sheet bendable to form aU-shaped channel piece defining the rear, top and bottom walls of thehousing, a

pair of flat end pieces defining the end walls of the housing and a flatpanel piece forming the front wall of the housing, the pieces being heldtogether by selftapping screws.

Also an object of the invention is to provide a module housing of theabove type in which the channel and panel pieces may be cut to variouslengths, the end pieces having a fixed length whereby module housings ofdifferent lengths may be assembled, all other dimensions thereof beingunchanged.

Still another object of the invention is to provide a console frameadapted to bring together a family of module housings in a continuousarray to form a control panel having a visually integrated form and apleasing appearance.

Briefly stated, these objects are accomplished by housings for controlmodules formed by four flat pieces, one of which is a sheet bendableinto a channel to define the rear and the top and bottom walls, thesecond and third of which are identical end-pieces to define the endwalls of the housing, and the fourth of which defines the front panelthereof. All of the pieces have a fixed width, but the channel and panelpieces may be cut to different lengths, whereby the housings formed byfastening the pieces together may be of different length, but areotherwise of the same dimensions. When modules of different length arearranged in side-by-side relation, they present a continuous, visuallyintegrated appearance. A console frame is provided which is adapted toclamp together an array of modules, the clamp being releasable wherebyindividual modules may readily be removed and replaced.

OUTLINE OF DRAWING For a better understanding of the invention, as wellas other objects and features thereof, reference is made to thefollowing detailed description to be read in conjunction with theaccompanying drawings, wherein:

FIG. l is an exploded view of a module housing in accordance with theinvention;

FIG. 2 is a perspective view of the module housing;

FIG. 3 is a partial side view of the module housing;

FIG. 4 is a perspective view of a console formed by a family of modules;

FIG. 5 is a plan view of an array of modules in the console;

FIG. 6 is a transverse section taken through the console; and

FIG. 7 is the same as FIG. 6, except that the module is swung upwardlyto obtain access to the rear thereof.

DESCRIPTION OF THE INVENTION Referring now to the drawing'and moreparticularly to FIGS. ll, 2 and 3, there is shown a preferred embodimentof the housing of an individual sub-section or module in accordance withthe invention. This housing, which has a box-like configuration, isconstituted by four components, namely channel piece 10, a pair of endpieces Ill and 12, and a panel piece 113.

Channel piece 110 is U-shaped to define the rear wall 10A and the topand bottom walls 10B and 10C of the enclosure. This piece is made ofsheet aluminum or other suitable metal that is bent to the desiredshape. Since all modules in accordance with the invention have the samedimensions except as to their lengths, which may be varied to suitparticular needs, all one need do in practice with respect to thechannel piece is to stock strips of aluminum sheeting all having thesame width, and to cut these strips to the desired length. In this way,one can provide channel pieces 1 foot long, 15 inches long, or inwhatever other length is specified.

Before the aluminum sheets are bent into the channel configuration,holes are drilled at points adjacent the corners of top wall 108 andbottom wall C. These holes are made to receive self-tapping screws 14ato 14d for attaching the end pieces 11 and 12 to the top and bottomwalls.

End pieces 11 and 12 are identical extrusions, preferably of aluminum,which are so profiled as to include longitudinally-extending parallelgrooves llA-l 1B, and 12A12B, respectively. These grooves aredimensioned to accept the self-tapping screws 14a to 14d for securingthe end pieces to top and bottom walls 10A and 1108. At the lower edgesof end pieces 11 and 12, there are formed grooves 11C and 12C, adaptedto accommodate the opposite ends of rear wall 10A of the channel pieceto provide a rigid support therefor. Ledges 11D and 12D are formed atthe top of end pieces 11 and 12, respectively, to accommodate the edgesof front panel piece 13.

Front panel piece 13, which is also an extrusion and which may be ofplastic rather than aluminum, is provided with twolongitudinally-extending grooves 13A and 13B adapted to receiveself-tapping screws 15a and 15d, passing through holes drilled near theends of ledges 11D and 12D on the end pieces. Front panel piece 13 isprovided with upper and lower ridges 13C and 13D which form comers inconjunction with ledges 11D and 121) on the end pieces and which definetherewith a rectangular frame enclosing the front panel. The dimensionsof this frame are somewhat larger than that of the box, thereby forminga shoulder facilitating console mounting with only the frame of themodule exposed.

Thus when the four pieces are assembled to create the box-like modulehousing as shown in FIG. 2, this housing is adapted to protectivelyenclose various mechanical and electronic components operating inconjunction with meters, dials, switches and other control andindicating elements mounted on the front panel of the housing.

End pieces 11 and 12 are always of the same size, regardless of thelength of the module housing. Hence a stock of identical end pieces maybe maintained to make boxes in various lengths. But channel piece 10 andpanel piece 13, while always of the same width, have a length dependingon the specified length of the module. Hence one need only stock longstrips of the channel and panel pieces and cut them to the desiredlength as the demand for a particular length arises.

This assembly technique is highly flexible and lends itself to thelow-cost production of a wide range of module-enclosure lengths, simplyby cutting standard preformed pieces to the particular lengths specifiedfor any given application. Thus an inventory for a substantial number ofmodules need consist only of an inventory of materials for the fourpieces.

We shall now consider, in connection with FIGS. 4 to 7, a console orcontrol panel made up of several modules, each of which is housed in amodule box of the type illustrated in FIGS. 1 to 3.

In order to bring together a significant number of sub-section units ormodules to form an unbroken array thereof having an aestheticallysatisfying appearance, one must be able to place the modules in a row inany desired order without any separation therebetween. ln this way,despite the fact that each module is selfsufficient and may be replacedwithout disturbing the connections to the other modules, the continuousarray thereof is visually integrated. Each module, regardless of length,has the same basic configuration, and the grouped modules create anattractive control console.

To accomplish this purpose, a console skeleton is provided, adapted toaccommodate a continuous array of modules of the same or varying length,the modules being placed and securely held in side-by-side relation,without any separation therebetween. The console skeleton includes ahorizontal main beam 16 having a small front flange 16A and a largerrear flange 168, both being normal to the beam surface. Hinged to frontflange 16A is a carrier strip 17 that is bent to define a section 17Aadapted to rest in the shoulder behind the front frame of the module box(see FIGS. 6 and 7), and along the top wall thereof.

Also provided is a base strip 18 adapted to rest in the shoulder behindthe front frame of the module box and along the bottom wall thereof,this strip having a downwardly extending front flange 18A and a rearflange 188. Module M and all other modules in the array are firmlyclamped between carrier strip 17 and base strip 18 in the manner to belater described.

Normally, the clamped modules, which swing from main beam 16, occupy asomewhat inclined position for improved viewability, as shown in FIG. 6,wherein the flange 18B of the lower strip 18 abuts a stationary anglebeam 19. When, however, access to the rear of the modules is desired inorder to make a change in connections, then one simply lifts up themodules in the manner shown in FIG. 7.

All cable connections are made at the rear of the module box; hence bythe present invention, access thereto may be had from the front of theconsole without having to approach the connections from the rear of theconsole, which rear may be inaccessibly placed against a wall or otherpieces of equipment. The modules themselves are free of protrusions ofany kind at top or bottom, all plugs, sockets and cable entries being atthe rear.

Referring now to FIG. 4, it will be seen that clamped between the strips17 and 18 are two modules M and M,, the latter being longer than theformer. In practice, the row of modules between the strips will usuallyextend the full length thereof to present a continuous integratedappearance.

In order to clamp the row of modules between the strips, clampingmembers are provided in the form of complementary plates 20 and 21,secured to the left end of strips 17 and 18, and complementary plates 22and 23 secured to the right end thereof, the plates having elongatedmatching slots therein to receive bolts. The slots permit relativemovement between the complementary plates for the purpose of adjustingthe space between the carrier and base strips 17 and 18.

Because of the slots in the clamps, the strips may be loose-fitting whenthe modules are first placed therebetween. When all modules occupy theirdesired positions,'the right and left end clamps are then tightened.Intermediate clamping force may be applied at intervals along the lengthof the console row by extending bolts 24 between strips 17 and 18 in thesmall clearing between modules in the row, which clearing is created bythe abutting module frames.

The clamping bolts are inserted in holes drilled in the strips after themodules are put into place between the strips 117 and 18, so that themodules may be freely slid into their proper position without suchmovement being obstructed. The clamping bolts completing the assemblyare positioned after the module layout for a particular application hasbeen determined.

While there has been shown and described a preferred embodiment ofcontrol module in accordance with the invention, it will be appreciatedthat many changes and modifications may be made therein withoutdeparting from the essential spirit of the invention.

What we claim is:

1. A control console comprising a. a console skeleton provided with acarrier strip supported from a horizontal beam and a base stripsupported in parallel relation to the carrier strip to define a spacereceiving a row of control modules,

b. a housing for each of said modules, said housings each beingconstituted by four pieces which are fastened together to form abox-like enclosure, said pieces consisting of a sheet bent into achannel piece defining the rear and the top and bottom walls of theenclosure, a pair of flat identical end pieces defining the end walls ofthe enclosure and a panel piece defining the front panel of theenclosure on which dials and other control elements are mounted, and

. means clamping said base strip to said carrier strip to hold saidmodules in said space, said carrier strip being hinged to saidhorizontal beam whereby said row of control modules may be raised toprovide access to the rear of the modules.

2. A console as set forth in claim ll, wherein said base strip issecured at its ends to said carrier strip by an adjustable clamp.

3. A console as set forth in claim 11, further including an angle beamdisposed to abut the edge of said base being hinged to said horizontalbeam whereby said row of control modules may be raised to provide 7access to the'rear of the modules.

5. A control console as set forth in claim 8 wherein said housingcomprises four pieces which are fastened together to form a box-likeenclosure, said pieces consisting of a sheet bent into a channeldefining the rear and the top and bottom walls of the enclosure, a pairof flat identical end pieces defining the end walls, and a panel piecedefining the front panel, said end pieces being provided withlongitudinally-extending grooves receiving self-tapping screws passingthrough holes in said top and bottom walls, said panel piece beingprovided with longitudinally-extending grooves receiving self-tappingscrews passing through holes in said end walls.

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1. A control console comprising a. a console skeleton provided with acarrier strip supported from a horizontal beam and a base stripsupported in parallel relation to the carrier strip to define a spacereceiving a row of control modules, b. a housing for each of saidmodules, said housings each being constituted by four pieces which arefastened together to form a box-like enclosure, said pieces consistingof a sheeT bent into a channel piece defining the rear and the top andbottom walls of the enclosure, a pair of flat identical end piecesdefining the end walls of the enclosure and a panel piece defining thefront panel of the enclosure on which dials and other control elementsare mounted, and c. means clamping said base strip to said carrier stripto hold said modules in said space, said carrier strip being hinged tosaid horizontal beam whereby said row of control modules may be raisedto provide access to the rear of the modules.
 2. A console as set forthin claim 1, wherein said base strip is secured at its ends to saidcarrier strip by an adjustable clamp.
 3. A console as set forth in claim1, further including an angle beam disposed to abut the edge of saidbase strip to maintain said modules at an inclined position.
 4. Acontrol console comprising: a. a console skeleton provided with acarrier strip supported from a horizontal beam and a base stripsupported in parallel relation to the carrier strip to define a spacereceiving a row of control modules, each of which includes a housingwhose height is the same for all modules but whose length may bespecified, and b. means to clamp said base strip to said carrier stripto hold said modules in said space, said carrier strip being hinged tosaid horizontal beam whereby said row of control modules may be raisedto provide access to the rear of the modules.
 5. A control console asset forth in claim 8 wherein said housing comprises four pieces whichare fastened together to form a box-like enclosure, said piecesconsisting of a sheet bent into a channel defining the rear and the topand bottom walls of the enclosure, a pair of flat identical end piecesdefining the end walls, and a panel piece defining the front panel, saidend pieces being provided with longitudinally-extending groovesreceiving self-tapping screws passing through holes in said top andbottom walls, said panel piece being provided withlongitudinally-extending grooves receiving self-tapping screws passingthrough holes in said end walls.